In this paper, we introduce the Prognostics and Health Management of gear bearing system using autoencoder neural networks. Bearings and gears are the most common mechanical components in rotating machines, and their health conditions are of great concern in practice. This study presents an outlier modeling method for forecasting the gear bearing system failure using the health indicators constructed from mechanical signal processing and modeling. Outlier modeling aims to find patterns in data that are significantly different from what is defined as normal. In the unsupervised outlier modeling setting, prior labels about the anomalousness of data points are not available. In such cases, the most common techniques for scoring data points for outlyingness include distance-based methods density-based methods, and linear methods. The conventional outlier modeling methods have been used for a long time to detect anomalous observations in data. However, this paper shows that autoencoders are a very competitive technique compared to other existing methods. The developed method is demonstrated using the IMS bearing data from NASA Acoustics and Vibration Database.

Remaining service life (RSL) of pavement, as a sign of future pavement performance, has always received growing attention from pavement engineers. The RSL describes the time from the moment of pavement inspection until such a time when a major repair or reconstruction is required. The conventional approach to determining RSL involves using non-destructive tests. These tests, in addition to being costly, interfere with traffic flow and compromise users' safety. In this paper, surface distresses of pavement have been used to estimate the pavement’s RSL in order to eliminate the aforementioned problems and challenges. To implement the proposed theory, 105 flexible pavement segments were taken from Shahrood-Damghan Highway (Highway 44) in Iran. For each pavement segment, the type, severity, and extent of surface damage and pavement condition index (PCI) were determined. The pavement RSL was then estimated using non-destructive tests include Falling Weight Deflectometer (FWD) and Ground Penetrating Radar (GPR). After completing the dataset, the modeling was conducted to predict RSL using three techniques include Support Vector Regression (SVR), Support Vector Regression Optimized by Fruit Fly Optimization Algorithm (SVR-FOA), and Gene Expression Programming (GEP). All three techniques estimated the RSL of the pavement by selecting the PCI as input. The Correlation Coefficient (CC), Nash-Sutcliffe efficiency (NSE), Scattered Index (SI), and Willmott’s Index of agreement (WI) criteria were used to examine the performance of the three techniques adopted in this study. In the end, it was found that GEP with values of 0.874, 0.598, 0.601, and 0.807 for CC, SI, NSE, and WI criteria, respectively, had the highest accuracy in predicting the RSL of pavement.

The remaining capacity can only be measured with offline method. This brings great challenge for the online prediction of Li-ion battery’s RUL. A novel online prediction method for Li-ion battery’s RUL was proposed, which is based on multiple health indicators (HIs) and can be derived from the batteries’ historical operation data. Firstly, four indirect HIs were built according to the battery’s operation current, voltage and temperature data respectively. On that basis, a generalized regression neural network (GRNN) was developed to estimate the battery’s remaining capacity, and the non-linear autoregressive approach (NAR) was utilized to predict the battery’s RUL based on the estimated capacity value. Furthermore, to reduce the interference, twice wavelet denoising were performed with different thresholds. A case study is conducted with a NASA battery dataset to demonstrate the effectiveness of the method. The result shows that the proposed method can obtain Li-ion batteries’ RUL effectively.

In the current industrial landscape, increasingly pervaded by technological innovations, the adoption of optimized strategies for asset management is becoming a critical key success factor. Among the various strategies available, the “Prognostics and Health Management” strategy is able to support maintenance management decisions more accurately, through continuous monitoring of equipment health and “Remaining Useful Life” forecasting. In the present study, Convolutional Neural Network-based Deep Neural Network techniques are investigated for the Remaining Useful Life prediction of a punch tool, whose degradation is caused by working surface deformations during the machining process. Surface deformation is determined using a 3D scanning sensor capable of returning point clouds with micrometric accuracy during the operation of the punching machine, avoiding both downtime and human intervention. The 3D point clouds thus obtained are transformed into bidimensional image-type maps, i.e., maps of depths and normal vectors, to fully exploit the potential of convolutional neural networks for extracting features. Such maps are then processed by comparing 15 genetically optimized architectures with the transfer learning of 19 pre-trained models, using a classic machine learning approach, i.e., Support Vector Regression, as a benchmark. The achieved results clearly show that, in this specific case, optimized architectures provide performance far superior (MAPE=0.058) to that of transfer learning which, instead, remains at a lower or slightly higher level (MAPE=0.416) than Support Vector Regression (MAPE=0.857).

This work can be considered as a first step of designing a future competitive data-driven approach for remaining useful life prediction of aircraft engines. The proposed approach is an ensemble of serially connected extreme learning machines. The results of prediction of the first networks are scaled and fed to the next networks as an additive features to the original inputs. This feature mapping allows increasing the correlation of training inputs with their targets by holding new prior knowledge about the probable behavior of the target function. The proposed approach is evaluated under remaining useful estimation using a set of “time-varying” data retrieved from the public dataset C-MAPSS (Commercial Modular Aero Propulsion System Simulation) provided by NASA. The prediction performances are compared to basic extreme learning machine and proved the effectiveness of the proposed methodology.

Reassessment of the fatigue life for wind turbines structural components is typically performed using deterministic methods with the same partial safety factors as used for the original design. However, in relation to life extension, the conditions are generally different from the assumptions used for calibration of partial safety factors; and using a deterministic assessment method with these partial safety factors might not lead to optimal decisions. In this paper, the deterministic assessment method is compared to probabilistic and risk-based approaches, and the economic feasibility is assessed for a case wind farm. Using the models also used for calibration of partial safety factors in IEC61400-1 ed. 4 it is found that the probabilistic assessment generally leads to longer additional fatigue life than the deterministic assessment method. The longer duration of the extended life can make life extension feasible in more situations. The risk-based model is applied to include the risk of failure directly in the economic feasibility assessment and it is found that the reliability can be much lower than the target for new turbines, without compromising the economic feasibility.

Concrete condition assessing penetrometers need to be able to distinguish between making contact with a hard (concrete) surface as opposed to a semi-solid (corroded concrete) surface. If a hard surface is mistaken for a soft surface, concrete corrosion may be over-estimated, with the potential for triggering unnecessary remediation works. Unfortunately, the variably-angled surface of a concrete pipe can cause the tip of a force-sensing tactile penetrometer to slip and thus to make this mistake. We investigated whether different shaped tips of a cylindrical penetrometer were better than others at maintaining contact with concrete and not slipping. We designed a range of simple symmetric tip shapes, controlled by a single superellipse parameter. We performed a finite element analysis of these parametric models in SolidWorks before machining in stainless steel. We tested our penetrometer tips on a concrete paver cut to four angles at 20∘ increments. The results indicate that penetrometers with a squircle-shaped steel tip (a=b=1,n=4) have the least slip, in the context of concrete condition assessment.

Estimating the remaining useful life (RUL) of components is a crucial task to enhance the reliability, safety, productivity, and to reduce maintenance cost. In general, predicting the RUL of a component includes constructing a health indicator ( ) to infer the current condition of the component, and modelling the degradation process, to estimate the future behavior. Although many signal processing and data-driven based methods were proposed to construct the , most of the existing methods are based on manual feature extraction techniques, and need the prior knowledge of experts, or rely on a large amount of failure data. Therefore, in this study, a new data-driven method based on the convolutional autoencoder (CAE) is presented to construct the . For this purpose, the continuous wavelet transform (CWT) technique is used to convert the raw acquired vibrational signals into a two-dimensional image; then, the CAE model is trained by the healthy operation dataset. Finally, the Mahalanobis Distance (MD) between the healthy and failure stages is measured as the . The proposed method is tested on a benchmark bearing dataset and compared with several other traditional construction models. Experimental results indicate that the constructed exhibits a monotonically increasing degradation trend and has a good performance to detect incipient faults.

This paper presents PrognosEase; a software that provides an easier way to produce different types of run-to-failure data mimicking real-world conditions to simplify prognosis studies in terms of data collection and improvement in ML degradation modelling process. Different types of degradation types made available to meet different types of applications. Besides, some primary ML tests were performed to ensure that complexity patterns of real systems could be observed in the training/testing predictions attitude. This paper also presents the impacts, limitations and potential improvements of the data generator.